Butter manufacturing process



Patented Apr. 12, 1949 UNITED STATES PATENT OFFICE BUTTER MANUFACTURINGPROCESS Original application December 6, 1940, Serial No.

368,750. Divided and this application November 2, 1945, Serial No.626,233

16 Claims. 1

The present invention relates to processes for producing milk fatconcentrate and butter. In

particular, the invention relates to improvements termilk. With theexception of the preliminary cream treatments and with the exception ofminor mechanical or apparatus changes, there has not been an importantor revolutionary improvement in methods adapted for the commercialmanufacture of butter, for many years.

This application is a division of our parent application Serial No.368,750, filed December 6, 1940, and entitled Butter process, now PatentNo. 2,423,834. The aspect of applicants invention directed to animproved butter product is claimed in applicants co-pendin'g applicationentitled Butter, Serial No. 741,088. The aspect of applicants inventionpertaining to the improved apparatus for processing a dairy product isclaimed in applicants co-pending application entitled Dairy system,Serial No. 741,089. The aspect of applicants invention pertainin to theimproved processing of a dairy product, such as cream, is claimed inapplicants co-pending application entitled "Dairy process," Serial No.741,090.

In the art of manufacturing butter, it has long been recognized that aneed existed for improvements in processes for producing butter. Priorinvestigators have suggested various modifications of such oldprocesses. Such suggested modifications have, however, generally failed.One of such suggested modifications proposed the use of a process forproducing butter from a plastic or super-cream, containing in theneighborhood of sixty-five percent (65%) milk fat. That particularmodification of the old processes of manufacturing butter, likeuntoother modifications, included a modification contemplating the use of aconverter or agitating means for the reversal ofthe phase of the milkfat in the cream, i.-e., changing the dispersed phase of the milk fat,which is present in the cream, to a continuous phase. Modifications ofthe mentioned type in the accepted processes for the manufacture ofbutter which call for the reversal of the phase of the milk fat in ahigh fat cream product have not been found to be satisfactory, and as aresult have not proved successful up to the present time.

It is an object of the present invention to provide an improved processfor producing milk fat concentrate.

It is also an object of the present invention to provide an improvedprocess for producing butter.

It is a further object of the present invention to'provide a continuousprocess for the production of butter having improved qualities andcharacteristics.

It is a still further object of the present invention to providecommercially satisfactory processes for producing milkfat concentrateand butter free from the common objectionablecharacteristics and aspectsassociated with butter made by prior usable butter manufacturingprocesses.

Other objects and advantages of the present invention will be moreapparent as the following description is considered. H

We have discovered commercially satisfactory processes for producingmilk fat concentrate and butter having the generally desired physicaland chemical characteristics and aspects. The improved processes, ingeneral, include the steps of introducing cream into a zone or chamberwherein the cream is subjected to subatmospheric pressure and whereinthe cream is subjected to the direct action of steam while under such areduced pressure, concentration of the milk fat in the cream beingprocessed by subjection of the cream, while at a temperature above themelting point of the milk fat content thereof, to a centrifuging action,separation of the concentrated milk fat, which has been thus obtainedand in which the fat portion thereof is in thecontinuous phase, fromother constituents of the cream, and thereafter working saidconcentrated milk fat product to produce butter having thedesiredphysical and chemical characteristics and aspects. The cream used intheabove process may or may not, as appears desirable, be pre-treated,although the use of a high quality, pasteurized creamis generallypreferred.

For a more complete understanding of the' nature and scope of theinvention, reference may be made to the following detailed descriptionthereof, to be read in connection with and with reference to theaccompanying drawing, wherein the single figure is a flow sheetdiagrammatically illustrating steps or sequences of operationscontemplated by this invention. 0

As illustrated in the drawing, cream having a milk fat concentration ofapproximately 30 percent to 40 percent is warmed in a prewarming vat lto a temperature of approximately F.

Jensen" type of pasteurizer.

to 110 F. (In the event that neutralization o! the cream to be used inthe process is desired. the neutralization may be carried out, forexample, in the prewarming vat I, in accordance with the generalpractice commonly followed in the buttermaking art.) From the vat I, thecream is pumped by pump 2 through conduit 8 into and through filter 4.Steam under a pressure of approximately 90 to 100 pounds per square inchis introduced into the conduit 3 at station 5 from a steam supply line5'. The mixture of the cream and steam in the conduit 8 raises thetemperature of the cream sufllciently so that the cream enters thefilter 4 at a temperature of approximately 135 F. From the filter l, thecream flows through conduit 6 into a hash pasteurizer "I, which may, forexample, be of the well recognized and commonly known Jensen" type.Steam is also introduced into a conduit 6 at station 8 from the steamsupply line 8. The mixture of the filtered cream with the steam in theconduit 8 raises the temperature of the cream sufllciently so that thecream enters the bottom of the pasteurizer from the conduit 8 at atemperature of approximately 150 F. to 160 F. The cream under generallyaccepted operating conditions remains in the pasteurizer I for a periodof time of approximately 10 to 15 seconds, during which period of timethe cream being pasteurized is heated to a temperature of approximately190 F. to 194 F. Such additional heating of the cream in the pasteurizer1 may be accomplished, for example, by the use of steam for indirectlyheating the cream in the manner common in the art of the well-known Thepasteurized cream flows from the pasteurizer 1 through conduit 9 to asupply tank ill, from which, in turn, it flows through conduit I I to azone of sub-atmospheric or reduced pressure for vacuum-steam treatment.

The cream having a temperature of approximately 175 F. to 190 F. isdrawn through the conduit II into the vacuum pasteurizer I2, in whichexists the zone of sub-atmospheric or reduced pressure and which vacuumpasteurizer may, if desired,-be of the type described in more detail inthe United States Patent No. 2,022,420. The pressure existing within thevacuum pasteurizer or chamber I2 is of a sub-atmospheric or reducednature and preferably is maintained at a reduced pressure ofapproximately 25 to 26 inches of mercury, as a result of which themaximum temperature within the chamber I2 will be approximately 130 F.to 135 F. Steam under a pressure of approximately 90 pounds per squareinch is introduced into the bottom of the vacuum pasteurizer or chamberI2 through the steam pipes I3, as illustrated in the drawing, wherebythe steam comes into direct contact with the cream within the chamber I2while the cream is under a reduced or sub-atmospheric pressure. Thedesired and preferred pressures and temperatures are readily maintainedin the chamber l2 by withdrawing vapor or volatile gases containingobjectionable flavoring materials through the passage H by means of anyconventional apparatus, such as a vacuum pump (not shown).

The treated cream, which has suflered praclimited thereto.

tically no net loss or gain in'its moisture content,

collects in the lower portion of the chamber l2,

at a temperature at least above the melting point of the various typesoi milk fats present in the cream being separated.

In the separator II substantially all of the milk fat is separated from.the proteins, skim milk, etc., and is discharged therefrom in a mixturein which the milk tat portion thereof is in the continuous phase and ina liquid form. The mixture containing the milk fat is expelled from theseparator at the station I! and contains approximately percent to 98percent milkiat, depending upon the extent of the above-mentionedcentrlfuging action. The major portion of such milk fat is in thecontinuous phase, and is nextpassed from station I8 through conduit I!to the vat 2|. From the vat 2| the milk fat product, with the milk tatstill in a liquid state and in the continuous phase, is pumped by pumpII through the conduits 22 and 23 to the mixing chamber 24. A controlledaqueous solution of salt, starternavors.

etc., may be pumped from the vat 25 by thepump 26 through the conduits21 and 23 into the mixing chamber 24, wherein su'ch aqueous solution mayis then conducted from the mixing chamber 24- through conduit 28 to acooling. and stabilizing unit 29, wherein the temperature of themixtureis reduced to a temperature of approximately 40 F. to 60 F. The cooledand stabilized mixture is conducted from the cooler and stabilizer 29through the conduit 38 into the tempering unit 3 I wherein the desiredtexture is imparted or developed in the butter thus produced. Thetempered product is forced from the tempering unit 3i and conductedthrough the conduit 32 to a suitable packaging machine (not shown).

It will be understood that the above representative detailed descriptionof the preferred method of practicing the improved process is merelyillustrative and that the present invention is not The pre-treatments,including filtering and pasteurizing the cream, may be modiiied oreliminated in whole or in part, as desired. Pasteurization of the cream,for example, may be performed entirely by mixing steam and cream. Theworking of the milk fat mixture after it is discharged from theseparator, including mixing the mixture with water and with salt or withbrine if salted butter is desired, etc., as well as the cooling andtempering, commonly referred to inthe art of buttermaking as aging, mayalso be modified if desired. Optimum conditions which may vary with theparticular type of milk fat present in the cream, which in turn varieswith the seasons of the year and the respective localities from whichthe cream is secured and the. feed which has been consumed by the cowsfrom which the milk is secured, may readily be determined by conductingconventional types of tests. commonly practiced in the art of buttermanufacture.

The temperatures and pressures in the vacuum pasteurizer l2 and in theseparator I'I, referred to in the preceding detailed description of theimproved process, of necessity represent one set of preferred conditionsfor the practice of the improved process. The mentioned illustrativetemperatures and pressures, however, may also be modified as desired andnecessary and optimum conditions, including the necessary time oftreatment within the vacuum pasteurizer (e. g. 5 to 30 minutes), shouldbe varied on the basis of the steam treatment is not fully understood.Our investigations indicate that subjecting the cream to sub-atmosphericpressure produced an expanhes the milk fat globules so that theyseparate into the continuous phase when later subjected to thecentrifuging action in the separator. Our investigations also indicatethat the best results are obtained when the cream entering the zone ofsub-atmospheric pressure is preheated to a temperature greater than thetemperature of saturated steam at a reduced or sub-atmospheric pressurewithin the mentioned zone. The fact that the fat is obtained in thecontinuous phase indicates that the complex protein-fat-hull or membranesurrounding the milk fat globules is modified physically or chemicallyor both by the combined vacuum and steam treatment in chamber [2. Itwill be understood, however, that the present invention is not limitedbytheoretical explanations.

The addition of a controlled amount of water to the concentrated milkfat enables the securing of a more uniform or finer dispersion of waterin a water-in-fat emulsion, resulting in an improved texture in thebutter made from such emulsion. The amount of water added varies withthe percentage of milk fat in the concentrated milk fat emulsion, whichconcentrated milk fat emulsion preferably contains 85 percent to 95percent fat. The amount of water thus added to the milk fat emulsion iscontrolled so that the final butter product contains at least 80 percentmilk fat.

The aspect of the present invention pertaining to the fine dispersion ofwater or brine in the milk fat emulsion and the low protein content ofthe emulsion, as well as the removal of substantially all of theoriginal water and water soluble materials from the milk fat which is tobe used for the manufacture of butter, enables the advantageous use ofthe invention in the production of a stable butter. A substantialproportion of nitrogenous material-one of the bacterial foods inbutter-is separated from the milk fat in the centrifugal separator.

As previously mentioned, the raw milk or cream as contemplated by thisinvention contains only approximately 35 percent milk fat. Theadvantages obtained by replacing the original nonfat materials of thecream with controlled water starter mixtures free from undesiredcontamination will be obvious to those skilled in the l the scope of thepresent invention are intended to be covered in the appended claims.

In the specifications and claims, the term "starter refers to startercultures. Such cultures are well known in the art of buttermaking andserve as means for flavoring the manufactured butter. In thespecifications and claims, the term cream is used with the thought thatit is to be given the ordinary or conventional meaning and is used toidentify a product in which the milk fat is in the dispersed phase, i.e.,

the milk fat dispersed as an emulsion in a continuous phase of non-fatmilk liquids. Cream art. An additional advantage of the presentinvention resides in the elimination of churning commonly carried outtoday, for the most part, in bacteria-contaminated wooden churns. Itwould be obvious to those skilled in the art that the milk fatconcentrate of the present invention is particularly adaptable for useas an intermediate in the preparation or manufacture of butter, in whichthe quality and composition of the concentrate may be accuratelycontrolled.

It will also be obvious to those skilled in the art that the mentionedmilk fat concentrate is also adaptable for use in the manufacture ofcheese, ice cream, frozen desserts, confections, baked goods and thelike.

It will be understood that the present invention is not limited to theillustrative process here in described. All modifications coming withinproducts differ materially from the concentrated fat or fat concentrate"of thepresent invention, in which "fat concentrate" the milk fat ispresent in the continuous phase.

The invention is hereby claimed as follows:

1. The process of making butterwhich comprises subjecting cream toreduced pressure, subjecting the cream While at said reducedpressure tothe direct action of steam, concentrating the milk fat contained in saidcream by subjecting the treated cream while at a temperature above themelting point of said milk fat to a centrifuging action and working theresulting milk fat concentrate obtained in the continuous phase by saidcentrifuging action so as to produce butter of the desired texture.

2. The process of making butter which comprises subjecting hot creamcontaining about 30 percent to 40 percent milk fat in the dispersedphase to reduced pressure, subjecting the cream while at said reducedpressure to the direct action of steam, concentrating the milk fat ofsaid cream by subjecting the treated cream at a temperature above themelting point of said milk fat to a centrifuging action, separating themilk fat concentrate obtained in the continuous phase by saidcentrifuging action from other constituent elements of said cream andworking the concentrated fat to produce butter.

3. The process of making butter which comprises introducing cream intoa. zone of sub-atmospheric pressure at a temperature substantiallygreater than the temperature of saturated steam at said pressure,subjecting said cream while at said reduced pressure to the directaction .of steam, concentrating the milk fat of said cream by subjectingthe treated cream while at a temperature above the melting pointof saidfat to a. centrifuging action, separating the resulting milk fatconcentrate obtained in the continuous phase by said centrifugingaction, adding a water mixture to said milk fat concentrate, and workingthe resulting fat-water mixture to produce butter.

4. The process of making butter which comprises subjectingwarmedpasteurized cream containing about 30 percent to 40 percent milkfat in the dispersed phase to reduced pressure so as to produceexpansion of said cream, subjecting the cream while at said reducedpressure to the direct action of steam under a substantial pres sure,concentrating the milk fat of the cream .in a continuous phase bysubjecting the treated cream while at a temperature above the meltingpoint of said milk fat to a centrifuging action, adding an aqueousmixture containing salt and starters to said milk fat concentrate, andworking the resulting mixture to produce a smooth product having atleast percent milk fat and the desired butter texture.

5. The process of making butter which comprises introducing pasteurizedcream at a temascaecc perature of approximately 175 F. to 190' 1". andcontaining approximately 35 percent milk fat in the dispersed phase intoa zone oi sub-atmospheric pressure, subjecting the cream while at saidreduced pressure to the action 01' highly compressed steam, withdrawingwater vapor from said zone so as to maintain the desired pressure at atemperature of approximately 130 F. to 132 F. within said zone,concentrating the milk fat of said cream by subjecting said treatedcream while at 'a temperature of approximately 125 F. to a centrifugingaction, separating the resulting milk fat concentrate containing about86 percent to 95 percent milk fat in the continu-,

one phase, adding a controlled aqueous flavor mixture containing saltand starter to said milk fat concentrate and then working the resultingI fat mixture to produce butters 8. The process of manufacturing butterwhich comprises subjecting pasteurized cream having a milk fatconcentration of approximately percent to percent to reduced pressure soas to produce an expansion of said cream, subjecting the cream while atthe reduced pressure to the direct action of highly compressed steam,concentrating the milk fat of said cream by subjecting said cream whileat a temperature above the a melting point of said-milk fat to acentrifuging action, said centrifuging action being adapted to obtain amilk fat product containing approximately 85 percent to 95 percent milkfat in the continuous phase, adding water and salt to the milk fatconcentrate product and working the resulting mixture to produce asmooth product containing in excess of .80 percent milk fat and havingthe desired butter texture.

7. In a continuous process for making butter the method of converting abutter-forming mixture of liquid milk fat in the continuous phase andwater which may also include salt and flavor starter into butter, whichcomprises simultaneously chilling andstabilizing the liquidbutterforming mixture, and developing a true butter texture in saidchilled butter-forming mixture by passing the sanie through a temperingunit.

8. A continuous buttermaking' process, which comprises subjecting creamcontaining milk fat in the dispersed phase to reduced pressure,subjecting the cream while at the reduced pressure to the direct actionof steam, concentrating the milk fat by subjecting the treated creamwhile at a temperature above the melting point of said fat to a centrifuing action, separating concentrated milk fat in the continuous phasefromsubstantially all of the other components of the cream, mixing themilk fat with water and desired amounts of salt and flavor starter insuch proportions as to provide a butter-forming mixture,

chilling the liquid butter-forming mixture, and developing-a true buttertexture in said chilled butter.

9. In a continuous process for makingbutter' fraction having the highmilk fat concentration to produce butter therefrom, and subjecting the 5ing means wherein to control the inter-crystalcooled butter to atempering operation to produce a true butter texture therein.

10. In a continuous process for making butter directly from cream,comprising subjecting the cream to force; eflective to destabilize thenormal milk fat in milk serum phase relation and extracting from thedestabilized cream a separation fraction containing a high concentrationof milk fat having the milk fat in the continuous phase, continuouslyadding metered quantities of standardizing ingredients to the separationfraction having the high concentration of milk fat to produce thereinthe desired butter composition, thoroughly intermingling thestandardizing. ingrediants in the separation fraction having a hilh milkfat concentration,- cooling and stabilizing the standardized separationfraction having the high milk fat concentration to produce buttertherefrom, and subjecting the cooled butter to a tempering operation toproduce a true butter texture therein.

11. A process for making butter from a dairy product containing milk fatin the dispersed phase and milk serum in the continuous phase,comprising flowing the dairy product through means for applyingmechanical stresses thereto wherebythe milk serum phase is disrupted anddispersed and the normally dispersed milk fat phase is merged i-nto acontinuous phase containing the dispersed milk serum in an unstablereadily separable serum in fat mixture, then separating the mixture toproduce a portion having a high milk fat concentration, addingstandardizing ingredients to the portion having the high milk fatconcentration to produce the desired butter composition therein, andthen simultaneously cooling and stabilizing the standardi'zedmixture tothoroughly cool and stabilize the components thereof and to crystallizeat least a substantial portion of the milk fat to thereby stabilize themixture and to granulate a substantial portion of the milk fat crystals,whereby butter having a close texture is produced.

12l A process for making butter from cream.

wherein the flowing stream of cream is subjected to forces eflective tobreak the normal milk fat in milk serum emulsion to produce-a reversephase milk serum in milk fat mixture wherein the fat and serum phasesare in unstable readily separable relation, subjecting the mixture to aI separating action to produce a portion having a high milk fatconcentration, adding butter composition ingredients to the portioncontaining the high milk fat concentration to produce the desired buttercomposition therein, then cooling and stabilizing the mixture containingthe concentrated milk fat and butter composition ingredients tothoroughly cool and stabilize the components of the mixture and tocrystallize at least-a substantial portion of the milk fat to therebystabilize the mixture and to granulate a substantial portion of the milkfat crystals, and developing a true butter texture in said butter byforcibly feeding the same through temper line structural growth of themilk fat crystals, whereby butter having a truebutter texture anddesired characteristics of spreadability is produced.

13. A process of producing butter from cream, comprising heating thecream to at least a milk fat melting temperature, subjecting the heatedcream to forces eifective to break the normal milk fat in milk serumemulsion and to produce a reverse phase milk serum in milk fat mixturehaving its milk fat and milk serum portions in unstable readilyseparable relation, separating" late a substantial portion of the milkfat crystals to thereby produce butter having the desiredcharacteristics of texture and spreadability.

14. A process for making butter, comprising the steps. of destabilizinga dairy product containing milkiat in the dispersed phase, separate ingthe destabilized dairy produce to secure a separation fraction having ahigh'concentration of milk fat in the continuous phase, continuouslyadding metered quantities of butter composition standardizingingredients to the separation fraction containing the high concentrationof milk fat to produce the desired butter composition therein,coollngand concurrently stabilizing the standardized mixture to producebutter.

15. A process for making butter, comprising the steps of destabilizing adairy product containing milk fat in the dispersed phase, separating thedestabilized dairy product to secure a separation fraction having a highconcentration of milk fat in the continuous phase. continuously addingmetered quantities of butter composition standardizing ingredients tothe separation fraction containing the high concentration of milk fat toproduce the'desired butter composition 10 therein, thoroughlyintermingling the separation fraction containing the high concentrationof milk fat with the standardizing ingredients, cooling and concurrentlystabilizing the standardized mixture to produce butter.

16. A process for making butter, comprising the steps of destabilizing adairy product containing milk fat in the dispersedphase, separating thedestabilized dairy product tosecure a separation fraction having a highconcentration of milk fat in the continuous phase, adding buttercomposition standardizing ingredients to the separation fractioncontaining the high concentration of milk fat to produce the, desiredbutter composition therein, cooling and concurrently stabilizing thestandardized mixture to produce butter.

HERMAN C. HORNEMAN. RALPH V. HUSSONG. SIDNEY N. QUAM.

BERNARD W. HAMMER.

REFERENCES CITED The following references are of record in the,

Number Name Date 1,509,086 North Sept. 16, 1924 2,150,944 Sharples Mar.21, 1939 2,168,376 Meulen et al. Aug. 8, 1939 2,299,440 Meulen et al.Oct. 20, 1942 2,423,834 Horneman et al. July 15, 1947 OTHER REFERENCESHunziker, "The Butter Industry, third edition, published by the author,La Grange, Illinois (1940), pages 304-309.

